Foreign object detector for non-contact charging device

ABSTRACT

A non-contact charging device for charging a battery in a vehicle includes a source resonator, and a foreign object detector. The source resonator is configured to transfer electrical energy to a capture resonator in a vehicle. The foreign object detector is configured to detect a foreign object proximate to the source resonator. The foreign object detector includes a vertical antenna configured to detect a foreign object above the source resonator, and a horizontal antenna configured to detect a foreign object beside the source resonator.

TECHNICAL FIELD OF INVENTION

This disclosure generally relates to a non-contact charging device, andmore particularly relates to a foreign object detector configured todetect a foreign object above and/or beside a source resonator of thedevice.

BACKGROUND OF INVENTION

Non-contact or wireless charging systems for electric vehicles orhybrid-electric vehicles have been proposed. Such systems are convenientfor charging the vehicles as it is not necessary to manually attach orinsert a charging device into the vehicle. Electromagnetic energy istransmitted or communicated from a source resonator typically located ina base unit on a parking surface under the vehicle to a captureresonator attached to the vehicle and typically located on the undersideof the vehicle. Because there is the potential for electromagneticenergy to be coupled to unexpected foreign objects proximate to thesource resonator and capture resonator, tools, toys, or pets forexample, it is advantageous to provide a means to detect such foreignobjects.

SUMMARY OF THE INVENTION

In accordance with one embodiment, a non-contact charging device forcharging a battery in a vehicle is provided. The device includes asource resonator, and a foreign object detector. The source resonator isconfigured to transfer electrical energy to a capture resonator in avehicle. The foreign object detector is configured to detect a foreignobject proximate to the source resonator. The foreign object detectorincludes a vertical antenna configured to detect a foreign object abovethe source resonator, and a horizontal antenna configured to detect aforeign object beside the source resonator.

In another embodiment, a non-contact charging device for charging abattery in a vehicle is provided. The device includes a sourceresonator, a reference antenna, and a variable gain amplifier. Thesource resonator is configured to transfer electrical energy to acapture resonator in a vehicle. The reference antenna is configured todetect a reference signal originating from the source resonator. Thereference antenna is configured to be less sensitive to a presence of aforeign object than a foreign object detection (FOD) antenna proximateto the reference antenna. The variable gain amplifier is configured toamplify a reference signal from the reference antenna.

Further features and advantages will appear more clearly on a reading ofthe following detailed description of the preferred embodiment, which isgiven by way of non-limiting example only and with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The present invention will now be described, by way of example withreference to the accompanying drawings, in which:

FIG. 1 is a side a non-contact charging system and device for charging abattery in a vehicle in accordance with one embodiment; and

FIG. 2 is perspective view of the device of FIG. 1 in accordance withone embodiment.

DETAILED DESCRIPTION

FIG. 1 illustrates a non-limiting example of a vehicle charging system,hereafter referred to as the system 10, for charging a battery 22 in avehicle 12. The system 10 generally includes a non-contact chargingdevice, hereafter the device 16, which typically includes a base unit 14located on a parking surface 18 such as a garage floor under the vehicle12. The device 16 is generally configured to transfer electrical energyfrom the base unit 14 to a capture resonator 20 located on the underside24 of the vehicle 12. The device 16 may include a control panel 26configured to, for example, indicate when the capture resonator iscentered over the base unit 14, and indicate a state of charge of thebattery 22, and regulate electrical energy delivered to the base unit14.

FIG. 2 illustrates a non-limiting example of the base unit 14. The baseunit 14 normally includes a protective cover which is not shown only tosimplify the illustration. The base unit 14 generally includes a sourceresonator 30 configured to emit the electromagnetic energy 32 toward thecapture resonator 20 (FIG. 1). It is believed to be undesirable tocouple or expose certain objects to the electromagnetic energy 32, sothe device 16 is equipped with a foreign object detector 34 configuredto detect a foreign object 36 proximate to the source resonator 30.

In this non-limiting example, the foreign object detector 34 includes avertical antenna 38 configured to detect a foreign object above thesource resonator 30, for example, between the source resonator 30 andthe capture resonator 20. It has been observed that some of theelectromagnetic energy 32 may travel or be emitted beyond the gap area42 defined by the source resonator 30 on the bottom and the captureresonator 20 on the top, so the device 16 may advantageously alsoinclude a horizontal antenna 40 configured to detect a foreign object(e.g. the foreign object 36) located beside the source resonator 30,i.e. outside of the gap area 42. In general, the vertical antenna 38preferentially detects electromagnetic energy originating or reflectingfrom a direction above the base unit and towards the capture resonator20, while the horizontal antenna 40 preferentially detectselectromagnetic energy originating or reflecting from a directioncharacterized as being in a radial or horizontal direction away from thebase unit 14.

By way of example and not limitation, the vertical antenna 38 may bearranged upon a substrate 44 or circuit board assembly of the device 16.The vertical antenna 38 may be advantageously located and within aperimeter of the substrate 44 where the perimeter of the substrate isgenerally determined by the shape of the source resonator. Such aconfiguration allows for the vertical antenna 38 to be better directedto detect a foreign object in the gap area 42. In contrast, thehorizontal antenna 40 may be coupled to the perimeter, but be configuredto ‘reach’ over the source resonator 30 and be oriented in a directionthat is characterized as being perpendicular to the vertical antenna.Such a configuration allows for the horizontal antenna 40 to be betterdirected to detect a foreign object lying on the parking surface 18outside of the gap area 42.

By way of further example, the vertical antenna 38 may include an arrayof vertically directed elements 46. With such a configuration, thesensitivity and focus of the vertical antenna 38 can be varied in orderbetter estimate the size, composition, and/or location of an object inthe gap area 42. In order to do this, the substrate 44 may include ordefine an electrical components are 48 where various electricalcomponents (not shown) known to those in the art can be connected toelectrical traces (not shown) on the substrate 44 and thereby form, forexample, a controller or processor of the foreign object detector 34.Likewise, the horizontal antenna 40 may include a plurality ofhorizontally directed elements 50, the functional combination of whichcan be varied in order better estimate the size, composition, and/orlocation of an object outside of the gap area 42.

As described above, the non-contact charging device (the device 16) forcharging the battery 22 in the vehicle 12 generally includes a sourceresonator 30 configured to transfer electrical energy (i.e. theelectromagnetic energy) to the capture resonator 20 in the vehicle 12.In order to determine an amount of the electromagnetic energy that isbeing emitted, the base unit 14 of the device 16 may include a referenceantenna 52 configured to detect a reference signal 54 originating fromthe source resonator 30. It is possible that one of the array ofvertically directed elements 46 could serve as a reference antenna.However, it has been observed that a reference antenna that is smallerthan the typical vertical element is advantageous as a reduced sizereference antenna is less sensitive to the presence of a foreign objectif one is present. That is, it is preferable for the reference antenna52 to have a sensitivity characteristic to the presence of a foreignobject that would be considered undesirable for use as one of thevertical elements. As such, the reference antenna 52 is preferably lesssensitive to the presence of the foreign object 36 than a foreign objectdetection (FOD) antenna (e.g. the vertical antenna and/or the horizontalantenna 40) proximate to the reference antenna 52.

Since using a smaller antenna for the reference antenna 52 means thatthe reference antenna 52 will be less sensitive, and that the referenceantenna may be used when the device is in a standby mode. The standbymode is when the device 16 is not charging the battery 22, but is‘looking’ for the vehicle to arrive and bring the capture resonatorclose to the base unit 14 so charging can be initiated. In the standbymode the source resonator 30 may be operated to emit a relatively lowamount of energy in order to allow detection of an approaching vehicle.

Because of the reduced signal from the reference antenna 52, thesubstrate 44 may advantageously include a variable gain amplifier,hereafter the amplifier 56, configured to amplify the reference signal54 detected by or output from the reference antenna 52. By providingvariable gain, the level of the signal from the reference antenna 52 canbe boosted to be better analyzed by the controller or processor of theforeign object detector 34.

Accordingly, the amplifier 56 may operate at a first selected gain whenthe device 16 is charging a battery 22 in the vehicle 12 so the signaldetected by the reference antenna is relatively strong, and operate at asecond selected gain greater than the first selected gain when thedevice is not charging a battery in the vehicle because the signaldetected by the reference antenna 52 is relatively weak. The gain of theamplifier 56 may be determined by a resistor value in a feedback loop ofthe antenna, as will be recognized by those in the art. As such, it maybe advantageous if the amplifier 56 includes a resistor network 58operable to determine the gain of the amplifier 56 to a plurality ofgain values. For example, the values of the various resistors in theresistor network 58 may be individually adjusted during a calibrationprocedure of the device 16 in order to compensate for normal variationsin other features of the device 16 that may influence the strength ofsignal output by the reference antenna 52.

The device 16 may also include a plurality of reference antennas 62arranged across the substrate 44, and a switching device 60 configuredto selectively connect one or more of the plurality of referenceantennas 62 to the amplifier 56. Having a selection of what is used as areference antenna can be used advantageously to self-diagnose the device16 and to better detect small foreign objects while operating in thestandby mode.

Accordingly, a system 10, and a device 16 for charging a battery in avehicle is provided. The device 16 includes a vertical antenna 38 and ahorizontal antenna 40 so foreign objects can be readily detect in manypossible direction, and a variable gain amplifier (the amplifier 56) sothe reference antenna 52 can be better optimized for monitoring areference signal output by the source resonator 30.

While this invention has been described in terms of the preferredembodiments thereof, it is not intended to be so limited, but ratheronly to the extent set forth in the claims that follow.

We claim:
 1. A non-contact charging device for charging a battery in avehicle, said device comprising: a source resonator configured totransfer electrical energy to a capture resonator in a vehicle; and aforeign object detector configured to detect a foreign object proximateto the source resonator, wherein the foreign object detector includes avertical antenna configured to detect a foreign object above the sourceresonator, and a horizontal antenna configured to detect a foreignobject beside the source resonator, wherein the vertical antenna isarranged upon a substrate of the device and within a perimeter of thesubstrate, and the horizontal antenna is coupled to the perimeter andoriented perpendicular to the vertical antenna.
 2. The device inaccordance with claim 1, wherein the perimeter is defined by the sourceresonator.
 3. The device in accordance with claim 1, wherein thevertical antenna includes an array of vertically directed elements andthe horizontal antenna includes a plurality of horizontally directedelements.